Washing machine with positive pressure moisture extraction

ABSTRACT

A washing machine for washing articles includes a housing and a drum mounted within the housing for rotation therein. A door is mounted to the housing, with the door being movable relative to the housing for providing access to the drum. An expandable bladder is mounted within the drum, with the expandable bladder being operable between an extended position for squeezing moisture from articles being washed and a retracted position.

CROSS-REFERENCE TO RELATED APPLICATION

This application claims the priority benefit of U.S. Provisional Patent Application 62/129,137 filed Mar. 6, 2015, which is hereby incorporated herein by reference.

BACKGROUND

Home laundry has generally been cleaned with the application of three forms of cleaning action: chemical action, such as with detergents and other cleaning chemicals; mechanical action, such as by agitation, tumbling, rubbing the clothes by hand; and heat, typically applied by heated water.

Some markets are “laundry pair” markets where much of the sales are of a matched washer and dryer set (the United States is such a “laundry pair” market). In Europe and in Asia, the separate sale of dryers is a fraction of the number of washers. This is because of the limited space in the home, limited drain and vent infrastructure, higher energy costs, and the inefficiency of small drum or condensing dryers which take hours to dry clothes.

Most washer machines sold are either top loader machines or front loader machines. A top loader washer machine design is shown in U.S. Pat. No. 5,829,277 of Wunderlich. The basic modern day top loading automatic washer consists of an outer drum, an inner basket with agitator, a drive motor, a suspension system, controls, a hot and a cold water fill, a drain pump, lid and outer housing. Many consumers consider the top loader to be more convenient than the front loader for loading and unloading. Typically, the outer and inner tubs (drums) are set on a vertical axis. Moreover, a type of combination top loader combination washer/dryer machine is shown in U.S. Pat. No. 5,457,969 of Roaf.

In a modern front load (horizontal) washer, the same sorts of elements are found as in the top load washer, but typically turned sideways on a horizontal axis without an agitator. A type of front loader washer machine is shown in U.S. Pat. No. 4,819,459 of Keith.

Typically, whether washing clothes or other garments in the top loader or the horizontal washer, the inner drum rotates at high speeds such that a centripetal force is applied to the saturated garments within the drum, thereby causing the moisture within the garments to escape through the holes for draining out of the drum. However, the centripetal force in current machines can only take out so much moisture from the garments, leaving a substantially moist garment requiring more drying time and ultimately more energy to dry the clothes.

Needs exists for improved systems and methods for extracting or removing moisture from the garments during the several wash cycles before drying the garments. It is to the provision of a washing machine with positive pressure moisture extraction meeting these and other needs that the present invention is primarily directed.

SUMMARY OF THE INVENTION

Generally speaking, the invention relates to a washing machine that employs an internal mechanical device (within the washing machine) to wring/squeeze excess moisture from wet articles in the washing machine. In one form, this internal mechanical device can comprise an extendable and retractable bladder.

Thus, in one example form the present invention comprises a washing machine for washing articles and includes a housing and a drum mounted within the housing for rotation therein. A door is mounted to the housing, with the door being movable relative to the housing for providing access to the drum. An expandable bladder is mounted within the drum, with the expandable bladder being operable between an extended position for squeezing moisture from articles being washed and a retracted position.

Optionally, the washing machine's extendable bladder is mounted to the door. Optionally, the bladder comprises a substantially flexible and fluid-tight bag, and by providing positive pressure within the bag, the bag expands to provide for expansion thereof within an interior portion of the drum. Moreover, preferably with the bladder in the extended position the bladder at least partially engages portions of the interior of the drum.

Optionally, the positive pressure can be provided by positive water pressure. Alternatively, the positive pressure can be provided by an air compressor. Optionally, the air compressor can be mounted within the housing and a fluid conduit can provide positive pressure between the compressor and the door. Optionally, the compressor is mounted to the door.

In one optional form, the drum is oriented vertically within the housing and the door is an upper lid. In another optional form, the drum is oriented horizontally within the housing. In a further optional form, the drum is oriented at an angle between horizontal and vertical.

Optionally, a vacuum pump can be provided for urging the bladder to return to the retracted position. Further, the vacuum pump can be fluidly connected to the drum for further assisting the bladder toward its extended position.

Optionally, the bladder is in the form of a replaceable cartridge that is removably mounted to the door. Further, preferably the bladder, when extended, has a size and shape generally corresponding to the drum. The bladder can be generally cylindrical and can include surface features formed along an outer periphery thereof.

In another example form, the present invention relates to a method of removing moisture from wet articles within a washing machine. The method includes providing a washing machine comprising a housing, a drum rotatably mounted within the housing, and a cover mounted to the housing for providing access to the drum. The method also includes providing an inflatable variable volume bladder, the bladder being movable between a first retracted, compact configuration and a second extended, expanded configuration. The method further includes positioning the bladder generally adjacent the drum. Additionally, the method includes providing positive pressure within the bladder, the positive pressure within the bladder increasing the volume of the bladder to the second extended, expanded configuration so that the bladder occupies a substantial portion of an interior of the drum, thereby pressing the wet articles with the bladder against an interior of the drum and thereby removing moisture from the articles.

BRIEF DESCRIPTION OF THE DRAWING FIGURES

FIG. 1 is a side view of a washing machine according to an example embodiment of the present invention.

FIG. 2A is a side view of a bladder extending from a lid according to an example embodiment of the present invention.

FIG. 2B is a side view of the bladder of FIG. 2A, showing the bladder being expanded by positive water pressure.

FIG. 3 is a side view of a top-loading washing machine according to another example embodiment of the present invention.

FIG. 4 is a side view of a front-loading washing machine according to another example embodiment of the present invention.

FIG. 5 is a side view of a tilted washing machine according to another example embodiment of the present invention.

FIG. 6 is a perspective view of an expanded bladder according to an example embodiment of the present invention.

FIG. 7 is a side view of a lid assembly according to an example embodiment of the present invention.

DESCRIPTION OF EXAMPLE EMBODIMENTS

Referring now to the drawing figures, in which like numerals refer to like elements throughout the several views, FIGS. 1-7 show particular aspects of a washing machine according to example embodiments of the present invention. In one example form, the washing machine of the present invention comprises a deployable bag or expandable bladder for extension within the drum and pressing against the clothes and squeezing the water from the clothes. According to some example forms, the washing machine generally performs at least one washing cycle and at least one rinse cycle. After the clothes are saturated, e.g., after the wash and rinse cycle(s), the bag can be deployed within the drum to extract water from the clothes. According to one example form, positive air pressure is provided within the bag to cause deployment of the bag from a retracted, compact position to an extended, expanded position (see FIG. 7). According to other example forms, the bag can be deployed and provided for extracting the moisture from the clothes in various other forms (as will be described below).

FIG. 1 shows a washing machine 10 according to an example embodiment of the present invention. According to example forms of the present invention, the washing machine 10 is a top loading machine comprising an outer casing or housing 12 and a drum 20 generally rotatably mounted within the housing 12 generally about a vertical axis X. The vertical axis X extends generally perpendicularly from a bottom portion of the housing 12, for example, the surface the washing machine 10 sits on a support or ground surface during operation. A lid assembly 30 is generally movably mounted to the housing 12 and provides for access to the drum 20 for loading and/or removing clothes. In example forms, a bladder or bag 40 is deployable relative to the lid 30, and wherein deployment of the bag 40 within the drum 20 provides for extraction of moisture within washed or rinsed clothes, for example, so that the subsequent drying process can be as efficient as possible. In this way, a substantial majority of moisture absorbed in the clothes is removed therefrom (e.g., so that the drying process can be performed much more quickly and efficiently).

According to one example form, extension and retraction of the bag can be provided by positive air pressure, for example, which can be in the form of a compressor, a blower, fan, other devices, etc. to fill the bag with positive pressure and cause the expansion thereof to an extended, expanded position. According to example forms, at least a portion of the bag 40 contacts the clothes CL within the drum when the bag is in the extended, expanded position, for example, to press the clothes CL against an interior surface 22 of the drum and squeeze the water from the clothes CL. According to some example forms, the bag 40 contacts at least a portion of an interior surface 22 of the drum when in the extended, expanded position.

According to some example forms, the compressor or other device providing positive pressure to the bag 40 can be equipped with a reservoir tank, for example, to provide a quicker deployment of the positive pressure within the bag, and thus, quicker expansion of the bag within the drum 40. According to one example form, the reservoir tank is capable of holding compressed air therein, which can be expelled within the bag 40 when desired. Experimental results will determine the appropriate size of the reservoir tank. Optionally, the compressor or other positive pressure device is not provided with a reservoir tank.

The bag 40 is generally formed from a flexible material defining a variable internal volume that is generally sealingly fitted with the lid and is movable relative thereto between a retracted, compact position within the lid assembly 30 and an extended, expanded or deployed position pressing against at least a portion of the clothes CL within the drum 20. In example forms, the bag 40 is generally flexible and comprises an internal chamber comprising a variable volume, for example, depending on whether air is being added to the chamber or a vacuum is pulling air out of the chamber, or both.

As depicted in FIG. 2A, the bag 40 is generally deployable and recallable relative to the lid assembly 30. According to one example form, the positive air pressure is provided by an air compressor 50. In the same manner, for recalling the bag to move the bag from the extended, expanded position to the retracted, compacted position, a vacuum pump or other form of suction may be provided such that the volume of the internal chamber of the bag is substantially reduced and the entirety of the bag is recalled and retracted within the lid assembly 30. Optionally, according to another example embodiment, the bag 40 is movable between the extended, expanded position and the retracted, compacted position by the input/output of water within the internal chamber (see FIG. 2B). For example, a water valve 60 or other fluid connector coupled with the lid assembly 30 or the bag 40 provides for inputting water within the bag to positively pressurize the internal chamber of the bag 40, for example so that the bag can press the clothes against an internal surface 22 of the drum 20. According to example forms, the pressure of the water at the home's water connection is utilized in providing positive pressure to the bag. In example forms, typical household pressure is between about 25-75 PSI. Optionally, a water pump or other pumping device or compressor can be used to further pressurize the internal chamber.

FIG. 3 shows a washing machine 100 according to another example embodiment of the present invention. As shown, the washing machine 100 generally comprises a housing 112, a drum 120 rotatably mounted within the housing, a lid assembly 130, and a deployable bag 140 mounted to the lid assembly 130. According to one example form, an air compressor 150 can be provided for providing positive air pressure within the internal chamber of the bag 40. Further, a vacuum pump 170 is positioned and connected to the drum 120, for example, so that the vacuum is pulling the bag against the interior surface of the drum 120 while the positive air pressure from the air compressor 150 is pushing the bag against the interior surface of the drum 120 (or at least against the clothes CL therein).

Optionally, rather than providing positive air pressure within the internal chamber of the bag 140, only the vacuum pump 170 is utilized to cause the bag to press against the clothes CL and squeeze the water therefrom. Preferably, the lid assembly 130 is generally sealed against the housing 212 and/or the drum 120 such that the area between the bag and the drum 120 is generally air tight. In this way, the vacuum pump can cause expansion of the bag against the interior surface of the drum 120.

FIG. 4 shows a washing machine 200 according to another example embodiment of the present invention. As depicted, the washing machine 200 generally comprises a housing 212, a drum 220 rotatably mounted within the housing 212 about a generally horizontal axis Y, and a lid assembly 230 generally movably mounted to the housing 212 for covering an opening that provides access to the drum 220. In example embodiments, the Y axis is generally parallel to the support surface on which the washing machine 200 is supported.

FIG. 5 shows a washing machine 300 according to another example embodiment of the present invention. As depicted, the washing machine 300 generally comprises a housing 312, a drum 320 rotatably mounted within the housing 312 about an axis Z that is generally offset at an angle a relative to the horizontal axis Y, and a lid assembly 330 movably mounted to the housing 312 for covering an opening that provides access to the drum 320. Preferably, a compressor 350 and/or vacuum 370 can be provided for causing the bag 340 to press the clothes CL against an interior portion of the drum 320.

FIG. 6 shows a bag 440 according to an example embodiment of the present invention. As depicted, the bag 440 is generally cylindrical in shape, which generally comprises substantially similar end surfaces 442 and an array of ring-like ribs 444 extending along the length thereof. Optionally, the bag can be shaped as desired. For example, according to one example form, the bag 440 is generally bellow-shaped or generally shaped like an accordion. The bag can be formed from Kevlar, fiberglass, rubber, plastic or other suitable natural and/or synthetic materials, which accommodates receiving air or water therein, and which can hold a seal to prevent the pressurized air or water from escaping.

In one example form, the bag comprises a durable, rigid outer layer and an impermeable inner layer. Optionally, the bag 440 comprises a single flexible, rigid and impermeable layer. Preferably, the bag is capable of operating at a pressure of between about 40-80 PSI, for example, at about 60 PSI according to example forms. Preferably, the bag can accommodate a maximum pressure of about 240 PSI. In some example forms, the bag 440 is generally substantially sealed and comprises a port or coupling formed therewith such that air and/or water can pass through, for example, within the internal chamber of the bag 440, or for example, out of the internal chamber of the bag 440. Optionally, according to other example forms, the bag generally comprises a substantially large opening comprising a ring fitted thereon for providing coupling and air-tight engagement with the lid assembly.

FIG. 7 shows a lid assembly 530 according to an example embodiment of the present invention. As depicted, the lid assembly 530 generally comprises a lid housing 532 having a cartridge assembly 534 removably mounted thereto. According to example forms, the cartridge assembly 534 generally comprises a cartridge housing 536 and a bag 540 mounted thereto. For example, in the event that the bag 540 is damaged or requires replacement, the cartridge assembly 534 can be removed for disposal and an unused cartridge assembly 534 can be snapped or coupled into place. Preferably, when the cartridge assembly 534 is mounted to the lid assembly 530, the bag 540 is substantially compacted and retracted within the lid housing 532 (see 542), for example, so that the lid assembly 530 can be manipulated without interference with the bag 540. Optionally, a compressor 550 can be provided within a portion of the lid assembly 530, for example, to fill the bag 540 with positive pressure. However, according to other example embodiments, the compressor can be mounted within the housing and communicate with the bag within the cartridge assembly or within the lid assembly.

Typically, the cartridge and bag thereof will be out of sight from a user in the retracted, compacted position. In the expanded, extended position, the bag 540 generally extends or protrudes from the lid assembly 530. According to one form, in the deployed position (e.g., expanded, extended position), the bag can block the air return duct and the exhaust duct (unshown), for example, so that the entirety of the moisture extracted therefrom moves within the drain. After the bag has been deployed and sufficient pressure exerted against the laundry load (typically only a few minutes), the bag is generally recalled to the retracted, compacted position. In example forms, bag recall can occur in a number of different ways. As described above, a vacuum could be introduced in the same port that the compressed air was introduced thereby drawing back the bag. Optionally, a main and secondary blower could be activated, thereby pushing the bag back to its original position. In the case of a bellow, the bag generally inherently wants to retract due to the spring-like construction thereof. One or any combination of the above could be implemented to affect the recall of the bag. With the above technique the wash water and rinse water can be expelled with far greater speed than washing machine relying on centripetal force. Further, water extraction is accomplished with far less energy.

According to another example embodiment, the present invention relates to a method of removing moisture from clothes or wet articles within a washing machine. The method generally comprises providing a washing machine having a housing, a drum rotatably mounted within the housing, and a lid mounted to the housing for providing access to the drum; providing an inflatable variable volume bladder, the bladder being movable between a first retracted, compacted configuration and a second extended, expanded configuration; positioning the bladder generally near the drum; providing positive pressure to the bladder, the positive pressure within the bladder increasing the volume of the bladder to the second extended, expanded configuration; substantially occupying an interior of the drum with the bladder; pressing the wet articles with the bladder against an interior of the drum; and removing moisture from the articles.

According to additional example embodiments of the present invention, other forms of water extraction may be provided for removing excess moisture and water from clothes CL after one or more of the wash and rinse cycle(s). For example, according to one example form, mechanical pressure may be provided within the drum to cause the clothes CL to be pressed against an internal surface of the drum. The mechanism may be in the form of a retractable piston with a plate mounted on an end thereof, for example, wherein the plate generally moves relative to the lid assembly to press the clothes CL against the inner surface of the drum. According to one example form, a plurality of links are pivotally mounted together to provide for movement of an end plate between a retracted position and an extended position. Further optional, hydraulics can be provided for movement of a piston or plate within the drum to contact and squeeze the clothes.

According to another example embodiment, the positive pressure extraction device of the present invention can be incorporated within a combination washer/dryer apparatus. Thus, while the positive pressure extraction is mainly used during the washing and rinsing of the clothes or article(s), the positive pressure extraction can be incorporated with an apparatus capable of both washing/rinsing and drying.

It is to be understood that this invention is not limited to the specific devices, methods, conditions, or parameters described and/or shown herein, and that the terminology used herein is for the purpose of describing particular embodiments by way of example only. Thus, the terminology is intended to be broadly construed and is not intended to be limiting of the claimed invention. For example, as used in the specification including the appended claims, the singular forms “a,” “an,” and “one” include the plural, the term “or” means “and/or,” and reference to a particular numerical value includes at least that particular value, unless the context clearly dictates otherwise. In addition, any methods described herein are not intended to be limited to the sequence of steps described but can be carried out in other sequences, unless expressly stated otherwise herein.

While the invention has been shown and described in exemplary forms, it will be apparent to those skilled in the art that many modifications, additions, and deletions can be made therein without departing from the spirit and scope of the invention as defined by the following claims. 

What is claimed is:
 1. A washing machine for washing articles and comprising: a housing; a drum mounted within the housing for rotation therein; a door mounted to the housing, the door being movable relative to the housing for providing access to the drum; and an expandable bladder mounted within the drum, the expandable bladder being operable between an extended position for squeezing moisture from articles being washed and a retracted position.
 2. The washing machine of claim 1, wherein the bladder is mounted to the door.
 3. The washing machine of claim 2, wherein the bladder comprises a substantially flexible and fluid-tight bag, and wherein by providing positive pressure within the bag, the bag expands to provide for expansion thereof within an interior portion of the drum.
 4. The washing machine of claim 2, wherein with the bladder in the extended position the bladder at least partially engages portions of the interior of the drum.
 5. The washing machine of claim 3, wherein the positive pressure is provided by positive water pressure.
 6. The washing machine of claim 3, further comprising an air compressor for providing the positive pressure within the bag.
 7. The washing machine of claim 6, wherein the air compressor is mounted within the housing and a fluid conduit is sealingly engaged to provide positive pressure between the compressor and the door.
 8. The washing machine of claim 1, wherein the drum is oriented vertically within the housing and the door comprises an upper lid.
 9. The washing machine of claim 1, wherein the drum is oriented horizontally within the housing.
 10. The washing machine of claim 1, wherein the drum is oriented at an angle between horizontal and vertical.
 11. The washing machine of claim 3, wherein the compressor is mounted to the door.
 12. The washing machine of claim 1, further comprising a vacuum pump for urging the bladder to return to the retracted position.
 13. The washing machine of claim 12, wherein the vacuum pump is fluidly connected to the drum for further assisting the bladder toward its extended position.
 14. The washing machine of claim 1, wherein the bladder is in the form of a replaceable cartridge that is removably mounted to the door.
 15. The washing machine of claim 14, wherein the bladder, when extended, has a size and shape generally corresponding to the drum.
 16. The washing machine of claim 15, wherein the bladder is generally cylindrical and comprises surface features formed along an outer periphery thereof.
 17. A method of removing moisture from wet articles within a washing machine, the method comprising: providing a washing machine comprising a housing, a drum rotatably mounted within the housing, and a cover mounted to the housing for providing access to the drum; providing an inflatable variable volume bladder, the bladder being movable between a first retracted, compact configuration and a second extended, expanded configuration; positioning the bladder generally adjacent the drum; providing positive pressure within the bladder, the positive pressure within the bladder increasing the volume of the bladder to the second extended, expanded configuration so that the bladder occupies a substantial portion of an interior of the drum, thereby pressing the wet articles with the bladder against an interior of the drum and thereby removing moisture from the articles. 